Tough yarn, knitted and woven fabric with cutting resistance and glove

ABSTRACT

The invention provides a core yarn of a tough yarn for knitting and weaving a glove and the other knitted and woven fabric which are suitable for a worker using a cutting tool to wear, are excellent in a flexibility and an economic efficiency, prevent a folded end of a hard fiber from being exposed to apply a sense of discomfort to a wearer, and have a cutting resistance, and a tough yarn which uses the core yarn. A core yarn of a tough yarn is formed by compounding a hard fiber and a molten fiber, and fusion bonding the molten fiber to the hard fiber. Further, the tough yarn is formed by winding a winding yarn to the core yarn. A lower layer fiber may be further included between the hard fiber and the molten fiber.

TECHNICAL FIELD

This invention relates to a glove which a worker wears in a work area, a steel product factory and a sheet glass factory where a cutting tool is used, a knitted and woven fabric which is used in clothes and the other fabric products, and a yarn which is used in the knitted and woven fabric, and relates to a core yarn including a fiber such as a metal fiber, a glass fiber, a carbon fiber and a polyarylate fiber, which is tough and is inferior in a flexibility (hereinafter, refer to as “hard fiber”), a tough yarn using the core yarn, a knitted and woven fabric which is provided with a cutting resistance, and a glove.

BACKGROUND ART

In the fabric product which is used in the work area, the steel product factory and the sheet glass factory where the cutting tool is used, particularly in the glove, a gaiter and an apron which the worker wears, there is required a so-called cutting resistance that the fabric product is not cut even if a cutting blade of the cutting tool is in touch therewith. A high-tenacity yarn such as a superdense polyethylene fiber and an aramid fiber which has been widely known as Dyneema (trade mark) has been widely employed as the yarn which is used in the glove and the clothes with the cutting resistance. In particular, the superdense polyethylene fiber is preferable for the yarn for knitting the glove which is used in the work area using the cutting tool.

Further, a yarn obtained by coating a metal thin line or a glass fiber with a polyethylene or a nylon has been used as a yarn which is used for the same purpose. This kind of yarn has no stretch property, and the metal thin line and the glass fiber tend to be bent or folded at an acute angle when being bent. Further, when knitting the glove by using this kind of yarn, a flexibility and a fit property are applied by interknitting a knitting yarn such as a polyurethane rubber and a crude rubber having a stretch property.

In Patent Documents 1 and 3, there is proposed a covering yarn obtained by coating a core yarn constructed by a metal thin line and an additional yarn with a covering, and a glove obtained by knitting with the yarn. Further, in Patent Document 2, there is shown a sewing yarn obtained by setting a metal yarn and a molten yarn as a core yarn and heating the core yarn after coating the core yarn with a winding yarn, thereby fusion bonding the metal yarn and the winding yarn via the molten yarn.

Further, in Patent Document 4, there is proposed a cutting prevention glove interknitted mainly employing a hard composite yarn in which a hard fiber such as a glass fiber is a core yarn and a thermoplastic synthetic fiber is a winding yarn, and a high-strength composite yarn in which a high-strength synthetic fiber is a core yarn and a thermoplastic synthetic fiber is a winding yarn. As the hard fiber, there is shown an example in which a hard composite yarn is formed by setting a glass filament bundle of 50 to 300 denier, and covering a temporary twisted yarn of a polyester multifilament yarn as a winding yarn around the core yarn.

CITATION LIST Patent Literature PATENT LITERATURE 1: WO 2007/15333 PATENT LITERATURE 2: Japanese Unexamined Patent Application Publication No. 2013-253337 PATENT LITERATURE 3: Japanese Unexamined Patent Application Publication No. 2012-21258 PATENT LITERATURE 4: Japanese Unexamined Patent Application Publication No. 2001-164411 SUMMARY OF INVENTION Technical Problem

As is pointed out by the Patent Document 1, in the glove which employs the inorganic fiber such as the metal fiber or the glass fiber as the core yarn and is knitted by the yarn coated with the polyethylene fiber or the nylon fiber, the folded end of the hard fiber which is bent or folded at the acute angle when being bent passes through the winding yarn and is exposed. In the glove which is directly installed onto a skin, there is a problem that the folded end of the inorganic fiber is directly in touch with the skin and applies a sense of discomfort. Particularly, in the case that the elastic yarn such as the polyurethane fiber or the crude rubber which is excellent in a stretch property is compounded with the metal fiber in order to improve the flexibility and the fit feeling, the folded end of the hard fiber tends to be exposed and apply the sense of discomfort to the wearer.

An object of this invention is to provide a cutting resisting glove, a cutting resisting apron and the other cutting resisting knitted and woven fabric which are excellent in a flexibility and an economic efficiency, prevent a folded end of a hard fiber from being exposed and applying a sense of discomfort to a wearer and have an excellent wear feeling, and a tough yarn which is used for them.

Solution to Problem

A core yarn 20 (20 a and 20 b) according to the inventions of claims 1 and 2 of the invention is a yarn forming a core of a tough yarn 30 (30 a) according to the invention of claim 5, wherein the yarn includes a hard fiber 1 which is compound processed (twisted or covered) 11 and a molten fiber 2, and the molten fiber 2 is molten 2 b according to a heating treatment 12 so as to be fusion bonded and integrated with the hard fiber 1.

A core yarn 20 (20 c to 20 e) according to the invention of claim 3 is a yarn forming a core yarn of a tough yarn 30 (30 c to 30 e) according to the invention of claim 6, wherein the yarn includes a hard fiber 1, a molten fiber 2 and a third fiber (a natural or synthetic fiber, refer to as “lower layer fiber” hereinafter and claims 3 which is arranged between the hard fiber 1 and the molten fiber 2, and the yarn is formed by compound processing (twisting or covering) 11 the hard fiber 1, the molten fiber 2 and the third fiber 3, and thereafter melting 2 b the molten fiber 2 according to a heating treatment 12 so as to fusion bond and integrate with the hard fiber 1 and the lower layer fiber 3 which is not molten.

The core yarn 20 of the invention is in a state in which the hard fiber 1 is coated partly or in a whole periphery with the resin 2 b of the molten fiber which is fusion bonded to the surface of the hard fiber 1. In the case that the molten fiber 2 employs a molten fiber which has a low melting point in its peripheral portion 2 b and has a high melting point in its center portion 2 a, there comes to a structure in which the high-melting point portion 2 a of the molten fiber 2 is not molten but is integrated in a state of being wound to the hard fiber 1.

The tough yarns 30 (30 a, 30 c to 30 e) and 40 (40 c to 40 e) of the invention is the yarn formed by winding a winding yarn 5 of nylon, polyester, polyethylene, aramid fiber, polyacrylate, or spider thread yarn to the core yarn 20, and is used for knitting and weaving the knitted and woven fabric having the cutting resistance.

A coating treatment 13 is preferably carried out after the heating treatment 12 of the composite yarn 10 (10 a and 10 c to 10 f), however, in the case that the core yarn includes the lower layer fiber 3 and the winding yarn employs the yarn 5 a which has a heat resistance, a tough yarn 40 can be formed by carrying out the coating treatment 13 before the heating treatment 12. In the tough yarn 30, the winding yarn 5 and the core yarn 20 are not fusion bonded. In the meanwhile, since the heating treatment 12 is carried out after the coating treatment 13 in the tough yarn 40, the winding yarn 5 and the core yarn 20 are fusion bonded by the molten fiber 2 which is molten 2 b.

The hard fiber 1 is constructed by a stainless fiber, a carbon fiber, a glass fiber or a polyacrylate fiber, and plural kinds of hard fibers can be compounded and used depending on the intended use. The stainless fiber is excellent in the light of the cutting resistance, and the glass fiber is excellent in the light of the economic efficiency. The stainless fiber preferably employs a single yarn having a wire diameter between 10 and 150 μm or the yarn obtained by compounding two or five yarns. Further, the glass fiber preferably employs a multi filament or spun yarn having 10 to 600 denier.

The molten fiber 2 can employ a low-melting-point polyester fiber, a low-melting-point polyamide fiber and a low-melting point polyethylene fiber. However, the low-melting-point polyester fiber is preferable, and the molten fiber having a high melting point in its center portion and a low melting point in its peripheral portion is particularly preferable. The core yarn 20 using the molten fiber mentioned above comes to a structure in which the low-melting-point portion in the peripheral portion of the molten fiber 2 is molten 2 b and is fusion bonded to the surfaces of the hard fiber 1 and the lower layer fiber 3, and the high-melting-point center portion 2 a is not molten and is twisted or covered with the hard fiber 1 and the lower layer fiber 3 (FIGS. 2, 3, 7, 12 and 16).

In the case that the metal fiber is used as the hard fiber, the molten fiber 2 preferably employs a molten fiber in which a cross sectional area of the molten fiber when being fusion bonded and integrated with the hard fiber is equal to or greater than a cross sectional area of the hard fiber. A twisting number of the molten fiber 2 and the hard fiber 1 which are compounded (twisted or covered) is between 40 and 2000 per 1 m, and preferably between 150 and 1000.

When a monofilament is used as the hard fiber 1, the molten fiber 2 after depositing may slip in a longitudinal direction and a protection of the hard fiber 1 against the folding may be insufficient. In this case, it is effective that two molten fibers 2 are provided, and two molten fibers 2 m and 2 n are set to the core yarns 20 b (FIG. 3) which are wound to the hard fiber 1 reversely each other, in the compound processing 11.

The lower layer fiber 3 can employ a polyester spun yarn and a blended yarn of the polyester and a cotton, however, a woolly ester, an ester, a nylon and a woolly nylon are preferable. The hard fiber 1, the lower layer fiber 3 and the molten fiber 2 are the fiber, the monofilament or the multifilament.

The knitted and woven fabric of the invention is a knitted and woven fabric between the tough yarns 30 and 40 of the invention and the other yarn not including the hard fiber, in which the tough yarns 30 and 40 appear more on one surface of the knitted and woven fabric obtained by knitting and weaving by means of a plating, an interlock stitch or a double cloth, and the other yarns 8 and 9 appear more on the other surface. In order to apply the flexibility to the knitted and woven fabric, it is preferable to employ a yarn having a great stretch property such as a polyurethane fiber or a crude rubber, as the other yarns 8 and 9.

Various knitted structures can be thought for the glove according to the invention, however, a structure which can be thought to be preferably preferable is a glove by using the tough yarns 30 and 40 as a ground yarn, using the elastic yarn 8 as an additional knitting yarn, and plating in such a manner that the ground yarn appears on an outer surface and the additional knitting yarn appears on an inner surface.

Effect of the Invention

The core yarn 20 according to the invention forms the lower layer fiber or the molten resin portion having the great elasticity in the portion where a bending strain becomes the greatest when the yarn is bent, that is, the outer peripheral portion of the yarn where the internal stress becomes the greatest, the stress applied to the hard fiber is lightened by the internal stress of the molten resin and the lower layer fiber which are integrated with the hard fiber, and the lower layer fiber and the molten resin are not broken even if the hard fiber is broken. Therefore, the knitted and woven fabric which is knitted and woven by the tough yarn according to the invention is hard to be exposed to the surface of the knitted and woven fabric in the folded end of the hard fiber 1, and a sense of discomfort called as a tingling feeling is not applied to the wearer.

According to the core yarns 20 c to 20 e obtained by integrating the hard fiber 1 and the lower layer fiber 3 with the molten fiber 2 which is molten 2 b, the hard fiber 1 is coated with the lower layer fiber 3 and the molten resin 2 b. As a result, the lower layer fiber 3 achieves a protection action against the breakage and the folding of the hard fiber 1, so that it is possible to obtain the tough yarn having more excellent flexibility and soft feeling than the core yarns 20 a and 20 b which is coated only with the molten resin 2.

Further, according to the knitted and woven fabric such as a plating, an interlock stitch and a double cloth obtained by additionally knitting the tough yarn of the invention and the other elastic yarn, for example, the polyurethane fiber and the crude rubber having the flexibility, it is possible to obtain the knitted and woven fabric which has a good texture and is excellent in the flexibility. The glove additionally knitted with the elastic yarn has the excellent flexibility and texture.

Therefore, on the basis of the provision of the various knitted and woven fabric, the working glove, the gaiter and the working apron by using the tough yarns 20 and 40 of the invention and the other yarn, it is possible to provide the glove and the other knitted and woven fabric which is excellent in the flexibility and the economic efficiency, does not apply any sense of discomfort to the wearer due to the exposure of the folded end of the hard fiber, and has the cutting resistance.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a block diagram showing a step of manufacturing a tough yarn according to first and second embodiments.

FIG. 2 is a schematic cross sectional view of a core yarn according to the first embodiment.

FIG. 3 is a schematic cross sectional view of a core yarn according to the second embodiment.

FIG. 4 is a schematic side elevational view showing a coating treatment according to the first embodiment.

FIG. 5 is a block diagram showing a step of manufacturing a tough yarn according to a third embodiment.

FIG. 6 is a schematic side elevational view showing a compound processing according to the third embodiment.

FIG. 7 is a schematic cross sectional view of a core yarn according to the third embodiment.

FIG. 8 is a schematic side elevational view showing a coating treatment according to the third embodiment.

FIG. 9 is a schematic side elevational view showing a compound processing according to a fourth embodiment.

FIG. 10 is a block diagram showing a step of manufacturing a tough yarn according to a fifth embodiment.

FIG. 11 is a schematic side elevational view showing a compound processing according to the fifth embodiment.

FIG. 12 is a schematic cross sectional view of a core yarn according to the fifth embodiment.

FIG. 13 is a schematic side elevational view showing a coating treatment according to the fifth embodiment.

FIG. 14 is a block diagram showing a step of manufacturing a tough yarn according to a sixth embodiment.

FIG. 15 is a schematic side elevational view showing a compound processing according to the sixth embodiment.

FIG. 16 is a schematic cross sectional view of a core yarn according to the sixth embodiment.

FIG. 17 is a schematic side elevational view showing a coating treatment according to the sixth embodiment.

FIG. 18 is a block diagram showing a step of manufacturing a tough yarn according to a seventh embodiment.

FIG. 19 is a block diagram showing a step of manufacturing a tough yarn according to an eighth embodiment.

FIG. 20 is a block diagram showing a step of manufacturing a tough yarn according to a ninth embodiment.

FIG. 21 is an explanatory view showing an example of a knitted fabric.

FIG. 22 is an explanatory view showing an example of a woven fabric.

DESCRIPTION OF EMBODIMENT

A description will be given below of embodiments according to the invention with reference to the accompanying drawings. In the drawings, reference numeral 1 denotes a hard fiber, reference numeral 2 denotes a molten fiber, reference numeral 3 denotes a lower layer fiber which is arranged between the hard fiber 1 and the molten fiber 2, reference symbols 10 a denote a composite yarn in which the hard fiber 1 and the molten fiber 2 are compounded (twisted or covered), reference symbols 10 c to 10 f denote a composite yarn in which the hard fiber 1, the lower layer fiber 3 and the molten fiber 2 are compounded, reference symbols 20 a and 20 b denote a core yarn in which the molten fiber 2 which is molten 2 b according to a heating treatment 12 is deposited to the hard fiber 1 and integrated, reference symbols 20 c to 20 e denote a core yarn in which the molten fiber 2 which is molten 2 b is deposited to the hard fiber 1 and the lower layer fiber 3 which is not molten and is integrated, reference symbol 30 a denotes a tough yarn which is obtained by winding a winding yarn 5 to the core yarns 20 a and 20 b, reference symbols 30 c to 30 e denote a tough yarn which is obtained by winding the winding yarn 5 to the core yarns 20 c to 20 e, and reference symbol 40 denotes a tough yarn in which a winding yarn 5 a is fusion bonded to the core yarns 20 c to 20 e by the molten fiber 2 which is molten 2 b.

FIGS. 1 to 4 are views showing first and second embodiments which are not provided with any lower layer fiber. FIGS. 5 to 20 are views showing third to ninth embodiments which include the lower layer fiber 3, in which FIGS. 5 to 9 are views showing third and fourth embodiments in which one hard fiber 1 and one lower layer fiber 3 are provided. FIGS. 10 to 13 are views showing a fifth embodiment in which two hard fibers 1 m and 1 n are provided. FIGS. 14 to 17 are views showing a sixth embodiment in which two lower layer fibers 3 m and 3 n are provided. FIGS. 18 to 20 are views showing seventh to ninth embodiments in which a heating treatment 12 and a coating treatment 13 in the third to sixth embodiments are reversed in the step order.

FIG. 1 is a block diagram showing a step of manufacturing a tough yarn 30 a according to the inventions of the first and second embodiments. The hard fiber 1 and the molten fiber 2 are compounded in a compound processing 11 according to a first step, and a heating treatment 12 is applied to the obtained composite yarn 10 in a second step and at least peripheral portion of the molten fiber 2 is molten 2 b and is attached to a surface of the compounded hard fiber 1. The yarn obtained by the heating treatment 12 is a core yarn 20 a.

The heating treatment 12 according to the second step in FIG. 1 is a treatment for melting at least the peripheral portion of the molten fiber 2 compounded in the hard fiber 1 and fusion bonded to the surface of the hard fiber 1 so as to integrate both the elements. Therefore, a heating temperature and a heating time are a temperature and a time required for the melting resin in which at least the peripheral portion of the molten fiber 2 is molten 2 b is fusion bonded to the surface of the hard fiber 1. In the case that the molten fiber 2 employs a molten fiber which has a high melting point in its center portion 2 a and has a low melting point in its peripheral portion, the heating temperature in the heating treatment 12 is a temperature at which the resin of the low-melting-point portion is molten and the resin of the high-melting-point portion 2 a is not molten.

FIGS. 2 and 3 are enlarged views schematically showing cross sections of the core yarns 20 a and 20 b according to the first and second embodiments obtained by the heating treatment, in which FIG. 2 shows an example of the core yarn in which one molten fiber 2 is wound to a multifilament glass fiber 1, and FIG. 3 shows an example of the core yarn in which a narrow molten fiber and a thick molten fiber are wound to a monofilament stainless fiber in reverse directions to each other.

In a coating treatment 13 according to the third step, the winding yarn 5 is wound to the core yarns 20 a and 20 b which are obtained in the second step. FIG. 4 is an enlarged side elevational view showing a state in the middle of the covering process in the coating treatment 13, and shows a state in which the winding yarn 5 forming the tough yarn is wound to the core yarn 20 a forming the core yarn. FIG. 4 is a single cover, however, may be, of course, a double cover. The tough yarn 30 a can be obtained by the third step.

FIGS. 5, 10 and 14 are block diagrams showing the steps of manufacturing the tough yarns 30 c to 30 e. In the compound processing 11 according to the first step, each of the hard fiber 1, the lower layer fiber 3 and the molten fiber 2 is compounded, and the heating treatment 12 is applied to the obtained composite yarns 10 c to 10 e in the second step and at least the peripheral portion of the molten fiber 2 is molten 2 b so as to be attached to the compounded hard fiber 1 and lower layer fiber 3. The yarns obtained by the heating treatment 12 are the core yarns 20 c to 20 e. The compound processing 11 may be carried out by one step, however, is generally carried by a plurality of twisting or covering steps.

As shown in FIGS. 6, 11 and 15, the lower layer fiber 3 is wound as an additional yarn to the hard fiber 1. The lower layer fiber 3 is wound in such a manner that the hard fiber 1 is exposed in relation to the lower layer fiber which is adjacent without completely covering the surface of the hard fiber 1. The preferable winding number of the lower layer fiber 3 is between 40 turns/m and 1000 turns/m, and more preferably between 100 turns/m and 350 turns/m. However, in the sixth embodiment in which two lower layer fibers 3 are provided, and the two lower layer fibers 3 m and 3 n are compounded according to a double cover processing generally as shown in FIG. 15, the lower layer fiber 3 m in the hard fiber 1 side in this case is preferably wound at 3 to 50 turns/m.

The molten fiber 2 is generally compounded according to the double cover processing in such a manner as to intersect the lower layer fiber (the additional yarn) which is wound to the hard fiber 1. More specifically, as shown in FIGS. 6, 11 and 15, the lower layer fiber 3 is wound as the additional yarn to the hard fiber 1, and the molten fiber 2 forming an upper winding yarn is wound in a reverse winding direction.

The compound processing in FIGS. 6 to 8 is a processing for the lower layer fiber 3 being wound to the hard fiber 1, may be set to a processing for the hard fiber 1 being wound to the lower layer fiber 3. FIG. 9 is a drawing showing a composite yarn 10 f in the processing mentioned above. Since the stretch property is provided in the core yarn, the wooly ester, the ester, the nylon or the woolly nylon is set to the lower layer fiber 3 and the hard fiber 1 is wound to the lower layer fiber in the compound processing 11, and the molten fiber 2 is wound thereon and the heating treatment is applied, and the winding yarn is wound to the core yarn. They are suitable for the knitted and woven fabric in which the higher flexibility is required.

The heating treatment 12 according to the second step is a treatment for melting at least a peripheral portion of the molten fiber 2 in the composite yarn 10 obtained by the compound processing 11 of the first step, and fusion bonding to the hard fiber 1 and the lower layer fiber 3 corresponding to a lower layer, thereby integrating three elements. Therefore, the heating temperature and the heating time are a temperature and a time at which at least the peripheral portion of the molten fiber 2 is molten 2 b and the molten resin is fusion bonded to the surfaces of the hard fiber 1 and the lower layer fiber 3.

FIGS. 7, 12 and 16 are enlarged views schematically showing cross sections of the core yarns 20 c to 20 e according to the respective embodiments obtained by the heating treatment 12. As shown in the drawings, the resin 2 b molten on the surface of the hard fiber 1 is fusion bonded to the surfaces of the hard fiber 1 and the lower layer fiber 3 corresponding to the lower layer in a state of being expanded from the center portion 2 a of the molten fiber which is not molten, and the high-melting-point portion 2 a corresponding to the center portion of the molten fiber is left within the molten resin 2 b in a state of being wound to the hard fiber 1 and the lower layer fiber 3 without being molten.

As mentioned above, the lower layer fiber 3 does not completely cover the surface of the hard fiber 1, but the hard fiber 1 is exposed between the wound lower layer fibers 3. The molten fiber 2 which is molten is fusion bonded to the surface of the hard fiber 1 in this exposed area. In the meantime, since the molten fiber 2 is compounded in such a manner as to intersect the lower layer fiber 3, the molten fiber 2 is fusion bonded to the lower layer fiber 3 in the intersecting portion.

In the coating treatment 13 according to the third step, the winding yarn 5 is wound to the core yarns 20 c to 20 e obtained in the second step.

FIGS. 8, 13 and 17 are enlarged side elevational views showing a state in the middle of the covering step in the coating treatment 13, and show a state in which the winding yarn 5 is wound to the core yarns 20 c to 20 e. These drawings show a single cover, however, may be, of course, a double cover. The tough yarns 30 c to 30 e can be obtained by the coating treatment.

In the case that the winding yarn 5 employs a yarn which has a heat resistance, that is, a winding yarn 5 a which is not molten during the heating treatment 1 melting the molten fiber 2 and fusion bonding to the hard fiber 1 and the lower layer fiber 3, the coating treatment 13 can be carried out before the heating treatment 12 as shown in FIGS. 18 to 20.

The compound processing 11, the heating treatment 12 and the coating treatment 13 according to the seventh to ninth embodiments in FIGS. 18 to 20 are respectively the same as the compound processing 11, the heating treatment 12 and the coating treatment 13 according to the third to sixth embodiments. The obtained tough yarn 40 is different from the tough yarns 30 c to 30 e according to the third to sixth embodiments, only in a point that the winding yarn is limited to the yarn 5 a having the heat resistance, and the molten fiber 2 molten by the heating treatment 12 is also fusion bonded to the winding yarn 5 a.

In a test which the inventors made by using the glass fiber as the hard fiber 1, the wooly ester as the lower layer fiber 3, and the woolly nylon, the woolly ester or the aramid fiber as the winding yarn, the function and the effect of the tough yarn are approximately the same as those of the tough yarns according to the third to sixth embodiment, as long as the kinds of the hard fiber, the lower layer fiber, the molten fiber and the winding yarn and the winding number thereof are the same.

The obtained tough yarns 30 and 40 can be knitted and woven independently or together with the yarn including the other hard fiber, however, is generally interknitted or combined woven with the other yarn which does not include any hard fiber. For example, when knitting a glove, it is possible to plate (additional yarn knit, FIG. 21) so that the ground yarns 30 and 40 appear on a surface of the glove and the additional knitting yarn 8 appears on an inner surface, by using the tough yarns 30 and 40 according to the invention as the ground yarn, and using a yarn which is excellent in a stretch property, a moisture absorbing property and a texture property, such as a yarn including a high elastic yarn, for example, the polyurethane fiber, the crude rubber, a bulky processing yarn and a yarn of a natural fiber, as the additional knitting yarn 8.

The plating is widely used as a knitting method in which different yarns are used in front and back surfaces, however, the double cloth and the interlock stitch are also known. Thus, it is possible to obtain a knitted and woven fabric having a nature in correspondence to an intended use of the knitted and woven fabric, such as the flexibility, the moisture absorbing property and the texture property, on the inner surface or the back surface, while having the cutting resistance and the toughness on the outer surface or the surface, by utilizing these techniques.

For example, as shown in FIG. 22, there is a woven fabric having a double structure which is obtained by weaving the outer layer 21 with the tough yarns 30 and 40 according to the invention, weaving the inner layer 22 with the other yarn 9 which is constructed by a fiber which is excellent in a tough feeling, and intermittently winding 9 a and connecting the other yarn 9 to the outer layer 21. The interlock stitch also forms the same two-layer knitted fabric as the double cloth.

TABLE 1 Hard fiber Molten fiber Twisting number Winding yarn Winding number 1 Glass yarn Polyester molten yarn 250 turns/m 55dtex (52 μm) 20/—(165 μm) 2 Glass yarn Polyethylene molten yarn 250 turns/m 55dtex (52 μm) 560dtex (223 μm) 3 Glass yarn Polyester molten yarn 350 turns/m Polyethylene 200 turns/m 55dtex (52 μm) 167dtex (124 μm) 220dtex (173 μm) 4 Glass yarn Polyester molten yarn 350 turns/m 55dtex (52 μm) 55dtex (71.6 μm) 5 Glass yarn Polyester molten yarn 350 turns/m 110dtex (74.5 μm) 167dtex (124 μm) 6 Glass yarn Polyester molten yarn 350 turns/m Polyethylene 200 turns/m 110dtex (74.5 μm) 280dtex (161 μm) 440dtex (346 μm) 7 Stainless thin line Polyester molten yarn 250 turns/m 30 μm 20/—(165 μm) 8 Stainless thin line Polyethylene molten yarn 250 turns/m 30 μm 560dtex (223 μm) 9 Stainless thin line Polyester molten yarn 350 turns/m Polyethylene 200 turns/m 30 μm 167dtex (124 μm) 220dtex (173 μm) 10 Stainless thin line Polyester molten yam 350 turns/m Polyethylene 200 turns/m 30 μm 55dtex (71.6 μm) 220dtex (173 μm) 11 Stainless thin line Polyester molten yarn 350 turns/m 80 μm 280dtex (161 μm)

Table 1 is a table showing examples of the tough yarns according to the first and second embodiments which the inventors of the present invention manufacture by way of trial. In this table, the glass yarns in the product numbers 1 to 4 are a glass fiber multifilament in which the raw wire number is 100, the glass yarns in the product numbers 5 and 6 are a glass fiber multifilament in which the raw wire number is 200, and a stainless thin line is a monofilament.

The molten fiber is a yarn constituted by a plurality of fibers each having a high melting point in its center portion and a low melting point in its peripheral portion, the product numbers 1 and 7 are the spun yarn, and the product numbers 2 to 6 and 8 to 11 are the multifilament. The molten fiber constituted by a plurality of spun yarns and the multifilament is formed into a monofilament shape constituted by a plurality of fibers 2 a which are not molten and left, and the molten resin 2 b integrally including them, according to the heating treatment 12 in FIG. 1, and the molten low-melting-point portion is fusion bonded to the surfaces of the glass yarn and the stainless thin line.

The winding yarn is a multifilament. Numerical value in parentheses of each of fields about the glass yarn, the molten fiber and the winding yarn corresponds to numerical value indicating a wire diameter on the assumption that a total cross sectional area of the fibers is one fiber.

According to the test made by the inventors, it is recognized that the tough yarns of the product numbers 3 and 6 and the product numbers 9 and 10 indicating the kind of the winding yarn in Table 1 are particularly excellent as the ground yarn which is used for knitting the cutting resistance glove according to the plating.

The core yarn using the stainless single yarn (monofilament) as the hard fiber 1 can not often coat the hard fiber 1 sufficiently due to generation of slip in a longitudinal direction of the yarn between the stainless and the molten resin. This problem can be solved by employing two molten fibers 2 m and 2 n as the molten fiber 2 and compounding them, as shown in FIG. 3.

TABLE 2 Molten fiber Twisting Twisting Twisting number number number Hard fiber 2m (T/M) 2n (T/M) Winding yarn (T/M) sus30μ · 35μ · 50μ 50D 350 50D 350 High-tension polyethylene 200D 300 GY38D 200 200 WE50D, 75D 200 100 300 WN30D, 50D, 70D 300 sus50μ · 60μ · 70μ 70D 350 50D 350 High-tension polyethylene 200D 300 GY50D, GY100D 200 200 WE50D, 75D 200 100 300 WN30D, 50D, 70D 300 50D 350 70D 350 High-tension polyethylene 200D 300 200 200 WE50D, 75D 200 100 300 WN30D, 50D, 70D 300 sus60μ · 70μ · 80μ 70D 350 70D 350 High-tension polyethylene 200D 300 GY100D 200 200 WE50D, 75D 200 100 300 WN30D, 50D, 70D 300 70D 350 70D 350 High-tension polyethylene 200D 300 200 200 WE50D, 75D 200 100 300 WN30D, 50D, 70D 300

Table 2 is a table showing the contents of the test which the inventors made about the core yarn 20 b shown in FIG. 3. More specifically, the test is made by winding the molten fiber 2 m to the hard fiber 1, thereafter winding the molten fiber 2 n so as to intersect the molten fiber 2 m forming the lower layer and compounding, and thereafter melting both the molten fibers 2 m and 2 n by applying the heating treatment 12. As a result of the test, it is confirmed that the problem mentioned above when using the monofilament stainless fiber can be solved.

The hard fiber, the molten fibers 2 m and 2 n and the winding yarn in Table 2 are described collectively in relation to a plurality of trial yarns having different twisting numbers, and the kinds of the fibers and the yarns described in plural lines in each of the fields indicate the manufacture by way of trial in relation to plural thickness sectioned by “,” in each of the fields.

In the table, GY denotes a multifilament of the glass fiber, sus denotes a stainless monofilament, molten fiber denotes a multifilament of a molten polyester, WE denotes wholly ester, WN denotes woolly nylon, PET denotes polyester, An denotes acryl, D denotes denier, μ denotes a wire diameter micron, and T/m denotes a twisting number per meter.

TABLE 3 Lower Twisting Twisting Twisting layer number Molten number number Hard fiber fiber (T/M) fiber (T/M) Winding yarn (T/M) GY38D WE30D 350 50D 350 High-tension polyethylene 200D 300 sus30μ · 35μ 200 200 WE50D, 75D 200 100 300 WN30D, 50D, 70D 300 GY50D WE50D 350 50D 350 High-tension polyethylene 200D 300 sus50μ · 60μ 200 200 WE75D, 150D 200 100 300 WN70D, 140D, 210D 300 GY100D WE50D 350 50D 350 High-tension polyethylene 200D 300 sus50μ · 60μ 200 200 WE150D, 300D 200 sus70μ · 80μ 100 300 WN140D, 210D 300 WE75D 350 70D 350 High-tension polyethylene 200D 300 200 200 WE150D, 300D 200 100 300 WN140D, 210D 300 WE50D 350 50D 350 High-tension polyethylene 400D 300 200 200 WE300D, 450D 200 100 300 WN210D, 420D 300 WE75D 350 70D 350 High-tension polyethylene 400D 300 200 200 WE300dD450D 200 100 300 WN210D, 420D 300 GY200D WE50D 350 50D 350 High-tension polyethylene 200D 300 sus50μ · 60μ 200 200 WE150D, 300D 200 sus70μ · 80μ 100 300 WN140D, 210D 300 WE75D 350 70D 350 High-tension polyethylene 200D 300 200 200 WE150D, 300D 200 100 300 WN140D, 210D 300 WE50D 350 50D 350 High-tension polyethylene 400D 300 200 200 WE300D, 450D 200 100 300 WN210D, 420D 300 WE75D 350 70D 350 High-tension polyethylene 400D 300 200 200 WE300D, 450D 200 100 300 WN210D, 420D 300

TABLE 4 Twisting Twisting Twisting Twisting Hard fiber Hard fiber number Lower layer number Molten number number 1m 1n (T/M) fiber 3 (T/M) fiber 2 (T/M) Winding yam (T/M) GY38D sus30μ 3 to 50 WE30D 350 50D 350 High-tension 350 polyethylene 200D GY50D sus30μ 3 to 50 WE30D 350 50D 350 High-tension 350 polyethylene 200D GY100D sus30μ 3 to 50 WE50D 350 50D 350 High-tension 350 polyethylene 400D GY200D sus30μ 3 to 50 WE50D 350 500 350 High-tension 350 polyethylene 400D GY200D sus30μ 3 to 50 WE75D 350 50D 350 High-tension 350 polyethylene 400D GY100D sus40μ 3 to 50 WE50D 350 50D 350 Aramid fiber 400D 350 GY200D sus50μ 3 to 50 WE75D 350 50D 350 Aramid fiber 400D 350

TABLE 5 Twisting Lower Twisting Twisting Twisting Lower layer number layer fiber number Molten number number Hard fiber 1 fiber 3m (T/M) 3n (T/M) fiber 2 (T/M) Winding yarn (T/M) sus40μ WE75D 3 to 50 WE75D 350 50D 350 High-tension 350 polyethylene 400D sus40μ PET spun yarn 3 to 50 WE75D 350 50D 350 High-tension 350 20/— polyethylene 400D sus40μ An spun yarn 3 to 50 WE75D 350 50D 350 High-tension 350 —/48 polyethylene 400D sus50μ WE75D 3 to 50 WE75D 350 50D 350 High-tension 350 polyethylene 400D sus50μ PET spun yarn 3 to 50 WE75D 350 50D 350 High-tension 350 20/— polyethylene 400D sus50μ An spun yarn 3 to 50 WE75D 350 50D 350 High-tension 350 —/48 polyethylene 400D

Tables 3, 4 and 5 are the tables respectively showing the examples of the tough yarns according to the third, fourth and sixth embodiments which the inventors of the present invention manufacture by way of trial. The hard fiber, the lower layer fiber, the molten fiber and the winding yarn in Table 3 are described collectively about a plurality of trial yarns having different twisting numbers, and the kinds of the fibers and the yarns described in plural lines in each of the fields indicate the manufacture by way of trial in relation to plural kinds sectioned by “,” in each of the fields.

The molten fiber is molten at least in a peripheral edge portion of each of the fibers according to the heating treatment 12, and is fusion bonded to the surfaces of the hard fiber and the woolly ester fiber in the lower layer, and a plurality fibers are solidified after being molten and are formed into a monofilament shape constituted by the molten resin 2 b (refer to FIGS. 7, 12 and 16).

In Table 3, the test is made in the case that the glass fiber multifilament is used as the hard fiber 1, and the case that the stainless monofilament is used as the hard fiber 1. In both cases, it is possible to apply an excellent flexibility and a good wearing feeling to the obtained tough yarn and knitted and woven fabric by arranging the lower layer fiber 3 between the hard fiber 1 and the molten fiber 2.

However, the core yarn using one stainless monofilament as the hard fiber can not often coat the hard fiber 1 sufficiently due to the weak fusion bonding force between the hard fiber and the molten fiber, and the flexibility of the knitted and woven fabric using the core yarn is not sufficient.

On the contrary, according to the fifth embodiment in which the hard fiber 1 is constructed by a twisted yarn of the glass fiber 1 m and the stainless fiber 1 n as shown in Table 4 and FIG. 11, and according to the sixth embodiment in which the lower layer fiber 3 is constructed by two lower layer fibers 3 m and 3 n having reverse winding directions as shown in Table 5 and FIG. 15, it is possible to enhance the flexibility of the core yarn or the tough yarn including the stainless monofilament which is excellent in the cutting resistance.

Practically, the embodiment shown in Table 4 is preferable in the case of attaching importance to the cutting resistance, and the flexibility can be also applied by employing the structure in which the stainless fiber 1 n is wound to the multifilament 1 m of the glass fiber. In the meantime, in the case of attaching importance to the flexibility, the embodiment shown in Table 5 can be employed.

REFERENCE SIGNS LIST

-   1 hard fiber -   2 molten fiber -   3 lower layer fiber -   5, 5 a winding yarn -   9, 9 elastic yarn -   10 (10 a, 10 c-10 f) composite yarn -   11 compound processing -   12 heating treatment -   13 coating treatment -   20 (20 a-20 e) core yarn -   30 (30 a, 30 c-30 e) tough yarn -   40 (40 c-40 e) tough yarn 

1. A tough yarn comprising: a core yarn in which a hard fiber and a molten fiber are compounded; and a winding yarn which is wound to the core yarn, wherein the molten fiber wound reversely each other is fusion bonded to the hard fiber and the molten fiber is not fusion bonded to the winding yarn.
 2. (canceled)
 3. A core yarn of a tough yarn, wherein a hard fiber and a molten fiber are compounded and deposited to form the core yarn, the core yarn further comprises a lower layer fiber which is arranged between the hard fiber and the molten fiber and is made of a natural fiber or a synthetic fiber, and the molten fiber is fusion bonded to the hard fiber and the lower layer fiber which is not molten.
 4. The core yarn according to claim 3, wherein the molten fiber is a fiber in which a melting temperature of a center portion in a cross section thereof is higher than a melting temperature of a peripheral portion, and only the peripheral portion is molten according to a heating treatment and is fusion bonded to the hard fiber.
 5. A tough yarn comprising: a core yarn; and a winding yarn which is wound to the core yarn, wherein the core yarn is the core yarn according to claim 3, and the molten fiber is not fusion bonded to the winding yarn.
 6. A tough yarn comprising: a core yarn; and a winding yarn which is wound to the core yarn, wherein the core yarn is the core yarn according to claim 3, and the molten fiber is also fusion bonded to the winding yarn which is not molten.
 7. A knitted and woven fabric of the tough yarn according to claim 1, and another yarn which does not include the hard fiber, wherein the tough yarn appears more on one surface of the knitted and woven fabric, and the another yarn appears more on another surface of the knitted and woven fabric.
 8. The knitted and woven fabric according to claim 7, wherein the another yarn is an elastic yarn.
 9. A glove knitted by the tough yarn according to claim 1 and an elastic yarn, wherein the tough yarn appears more on an outer surface of the glove, and the elastic yarn appears more on an inner surface of the glove.
 10. The tough yarn according to claim 1, wherein the molten fiber is a fiber in which a melting temperature of a center portion in its cross section is higher than a melting temperature of a peripheral portion, and only the peripheral portion is molten by a heating treatment so as to fusion bonded to the hard fiber
 11. A tough yarn comprising: a core yarn; and a winding yarn which is wound to the core yarn, wherein the core yarn is the core yarn according to claim 4, and the molten fiber is not fusion bonded to the winding yarn.
 12. A tough yarn comprising: a core yarn; and a winding yarn which is wound to the core yarn, wherein the core yarn is the core yarn according to claim 4, and the molten fiber is also fusion bonded to the winding yarn which is not molten.
 13. A knitted and woven fabric of the tough yarn according to claim 5, and another yarn which does not include the hard fiber, wherein the tough yarn appears more on one surface of the knitted and woven fabric, and the another yarn appears more on another surface of the knitted and woven fabric.
 14. The knitted and woven fabric according to claim 13, wherein the another yarn is an elastic yarn.
 15. A knitted and woven fabric of the tough yarn according to claim 6, and another yarn which does not include the hard fiber, wherein the tough yarn appears more on one surface of the knitted and woven fabric, and the another yarn appears more on another surface of the knitted and woven fabric.
 16. The knitted and woven fabric according to claim 15, wherein the another yarn is an elastic yarn.
 17. A knitted and woven fabric of the tough yarn according to claim 10, and another yarn which does not include the hard fiber, wherein the tough yarn appears more on one surface of the knitted and woven fabric, and the another yarn appears more on another surface of the knitted and woven fabric.
 18. The knitted and woven fabric according to claim 17, wherein the another yarn is an elastic yarn.
 19. A glove knitted by the tough yarn according to claim 5 and an elastic yarn, wherein the tough yarn appears more on an outer surface of the glove, and the elastic yarn appears more on an inner surface of the glove.
 20. A glove knitted by the tough yarn according to claim 6 and an elastic yarn, wherein the tough yarn appears more on an outer surface of the glove, and the elastic yarn appears more on an inner surface of the glove.
 21. A glove knitted by the tough yarn according to claim 10 and an elastic yarn, wherein the tough yarn appears more on an outer surface of the glove, and the elastic yarn appears more on an inner surface of the glove. 